MULTIFUNCTION SINGLE LEVER CONTROL FOR LIFT TRUCKS

Abstract: A single lever hand control (34) for multiple functions having two distinct axes of movement (46, 52). In a stand-up, battery powered lift truck (10) having a mast (20), and a carriage (24) with forks (27), an operator stands facing the side with reference to the direction of travel. Movement of the control lever (34) right to left from a neutral position relative to the direction the operator is facing controls the forward and reverse direction and the speed of the truck. The mast (20) and carriage (24) operations are controlled by the lever (34) being pushed or pulled transversely to the direction of travel. The force required to displace the lever (34) in one direction being less than that required in the other being consistent with the large muscle groups. The movement of the lever (34) is also consistent with the direction of movement of the particular function being performed.

Description: MULTIFUNCTION SINGLE LEVER CONTROL FOR LIFT TRUCKS _1 Field of the Invention 2 ^ This invention pertains to multifunction controls for electric powered lift trucks and more particularly to a stand- up truck control having a single lever hand control. 5 6 ^ . Background of the Invention Operator controls for stand-up, narrow aisle, lift trucks j} having a single hand lever are desirable because they are easy to operate, take little training to master, improve 10 productivity and are less prone to operator error. 11 A type of control system for such trucks is one that uses 12 functional switches which the operator can select by pressing 13 a button to condition the electric circuit for the desired 14 function. A manual control is then actuated to cause the 15 resulting movement, such as tilting the forks. 16 One potential difficulty with this type of control is 17 that it may not always coordinate adequately the physical 18 movement of the control lever with the mental or cognitive 19 activity in selecting the function especially where the single 20 lever also controls forward or reverse and the mast functions 21 as well. 22. 23 Summary of the Invention . The present invention pertains to a multifunction single 2 ^ lever control in which the functions are more closely 3 ^ coordinated with the physical movement of the control lever. 4 ^ Different hand, arm and shoulder motions of the operator are _5 associated with two directional axes of movement of the lever in a horizontal plane. 1_ In a preferred embodiment of the invention, the operator f3 is positioned at an angle facing sideways to the direction of travel rather than facing in the direction the truck is 0 travelling, either forward or reverse. The single lever 1 control is accessible to the operator in a standup position 2 with the hand resting comfortably on a grip at about waist 3 level. The two axes of operation, one in the direction of 4 travel, controlling the truck speed and direction, and the 5 other in the direction which the operator is facing, 6 controlling the functions of the mast, are related to the 7 movements they control, e.g., with the operator facing 8 laterally to the direction of travel, right is forward, and 9 left is reverse for causing the truck to travel in the 0 corresponding direction. 1 Different sets of muscles are employed in operating the 2 lever along one axis as opposed to the other which 3 differentiates the "feel" in the two axes of operation from 4 different reactive forces required by the mechanism. The 5 larger forces will be encountered by the large muscle groups 6 in the operator's back, shoulder and arm in a push-pull motion 1 ^ along the one axis laterally to the direction of travel 2 ^ employed in controlling the mast functions, while the smaller muscle groups of the hand and wrist are employed along the 4 ^ other axis in a right and left rolling motion used for 5_ controlling the speed and forward or reverse travel of the truck. In the particular application of the control on a standup, battery-operated lift truck, the traction motor for £ propelling the truck in either forward or reverse directions 0 is initiated for drive in one, or the other direction, and a 1 transducer, which requires only a small amount of effort to 2 operate, varies the voltage to the motor a d hence the speed 3 of a drive steer wheel. In the case of a standup lift truck, 4 this is a single steerable drive wheel. 5 The mechanical parts of the control include a multiaxis 6 cradle assembly on which the single hand lever is gimbaled. 7 A shaft rotates with the lever when moved forward or reverse 8 along the one axis generally parallel to the direction of 9 movement of the truck. The shaft in turn rotates a cam that 0 actuates a forward or reverse directional switch. The switch 1 conditions the power circuit to drive the motor in either 2 direction to propel the truck in either a forward or reverse 3 direction. A transducer is operated by the shaft to vary the 4 voltage to the motor and hence, the speed proportional to the 5 displacement of the lever. 6 The cradle assembly also incudes a collar rotated on the _1 other axis, in the direction the operator is facing, employing 2_ the push-pull motion of the lever. The collar rotates a cam that actuates switches which in turn condition the circuit for a selected mast function, e.g., pushing the lever lowers the 5 mast, pulling it toward the operator raises it. J5 Selector buttons on the grip are provided to isolate 1_ portions of the circuit for different mast functions, e.g., j3 side shift or tilt or reach/retract, when the lever is pushed or pulled. 0 Thus, the invention has as one of its objects a single 1 lever control which more nearly matches the large muscle 2 groups of the operator with the larger reactive forces of the 3 control and the smaller muscle groups with the smaller 4 reactive forces of the control to create less fatigue and 5 higher productivity during long periods of operation of 6 industrial equipment. 7 A principal object of the preferred embodiment is that 8 the reactive force encountered in producing the travel mode of 9 the truck has a "feel" that requires the least amount of force 0 from the operator, referred to as the "X" direction, while the 1 larger muscle groups of the operator's back, shoulder and arm 2 are employed in a push-pull manner to counteract the larger 3 forces in a "Y" direction producing a distinctly different 4 "feel" for operating the mast functions of the truck. 5 Another object is to use control movements in a direction 6 aligned with the function being controlled to reduce the 1 learning time for operating the equipment as well as making it 2 ^ more efficient and user-friendly by employing the natural movements of the operator to mimic the same direction in which the controlled function is being performed. j5 Other objects and advantages of the invention will be j more readily apparent by reference to the following detailed 1_ description of the control in conjunction with the j3 accompanying drawings, wherein: 9 0 Brief Description of the Drawings 1 Fig. 1 is a rear perspective view of a standup industrial 2 truck employing the single lever control; 3 Fig. 2 is an exploded view of the control mechanism; 4 Fig. 3 is a hydraulic circuit diagram of the hydraulic 5 system that is operated by the control in Fig. 2; and 6 Fig. 4 is an electrical circuit diagram of the truck 7 pictured in Fig. 1. i 9 Description of the Preferred Embodiment 0 Pictured in Fig. 1 is a powered industrial lift truck 1 referred to in the industry as a standup, narrow aisle, reach 2 truck. The truck (10) has a chassis (12) providing an. 3 operator's compartment (13) in which an operator stands when 4 operating the truck. A single drive/steer wheel (not shown) 5 in the rear propels and maneuvers the truck while a pair of 6 outriggers (16), one on each side at the front of the chassis, 1 ^ includes wheels (17) supporting the truck at the front. An 2_ integral drive motor and drive gear assembly is mounted within _3 the sheet metal panel (18). A mast (20) has spaced outer fixed rails (21) which receive telescopically, vertically 5_ extendable, intermediate and inner rails (22, 23). A pantograph carriage linkage (24) supports a load backrest (25) and carries forks (27) for engaging and lifting a load. The 8> pantograph carriage (24) is raised on the inner rails and the linkage reaches out and retracts. From the position shown in 0 Fig. 1, the linkage will retract the load backrest and forks 1 to the front of the mast (20). When the vertical lift 2 function of the mast is performed, the pantograph carriage, 3 and then the inner rails (23), and the intermediate rails (22) 4 are raised to reach a maximum overall height of about 20 feet. 5 The maximum lift height would vary, depending upon the weight 6 of the battery (28) and the configuration of the mast (20), 7 but typically a triplex mast, as illustrated in Fig. 1, is 8 capable of reaching heights of 21-1/2 feet (approximately 10 9 meters) with a load of 2,000 pounds (906 kilograms) on 0 standard forks. A tilt cylinder (not shown) is capable of 1 tilting;.the forks (27) 4° to the rear and 3° to the front from 2 a horizontal plane in which the forks (27) are normally 3 situated so that the tips can slide under a pallet, box, or 4 crate in picking up a load, after which the forks are tilted 5 back and the pantograph linkage (24), if extended, is 6 retracted to the front of the mast (20). Travel speeds vary 1. up to 0-7 mph, with the truck being propelled by the drive 2 ^ wheel in either forward or reverse directions. Steering lever (30) turns the drive wheel. A brake pedal (32), which the operator stands on during travel, is released for parking or 5_ emergency braking. All of the functions of the truck, except braking and 2 steering are controlled from the operator's compartment by a 8 single hand lever (34). A palm shaped grip incorporates a row £ (35) of selector buttons along the side of the grip within 0 convenient access of the thumb of the operator. 1 Fig. 2 is an exploded view of the control mechanism 2 operated by the single lever control handle (34). The grip 3 has mating halves 34a, 34b, shown separated in Fig. 2 on 4 opposite sides of a rod (37) to which they are secured by 5 fasteners (38) when assembled as pictured in Fig. 1. The row 6 (35) of selector buttons is housed within an electrical unit 7 (40) from which buttons (41, 42, 43) project through one side 8 (34a) of the grip so as to be accessible by the operator's 9 thumb when his palm is resting on the grip. The top button 0 (41) controls the reach function of the pant: graph, the middle 1 button (42) the tilt function, and the lower button (43) the 2 side shift function of the carriage, as will be more fully 3 described hereinafter. In addition, a horn button (44) is 4 provided on the top of the grip which the operator depresses 5 with the index or middle finger of his hand. 6 The rod (37) is secured to a shaft (45) which causes 1 ^ rotation of shaft assembly extension (45a) biased to a neutral 2 position by spring (45b). Shaft assembly extension (45a) rotates about axis (46) of an internal bushing (48) in a 4_ collar (49) which is gimbaled on pins (50) which pivot on axis 5_ (52). A cradle (53) has slots (54) in which the pins (50) 6_ pivot. The cradle (53) is secured to a plate (55) mounted to 2 the chassis of the truck. A pair of links (57) are fastened at one end to the collar (49). They are pushed or pulled by £ rotation of the collar around its axis (52) to operate a pair 0 of hydraulic control valves (59, 60). 1 Forward or reverse directional switches (62, 63) opposite 2 a cam (47) are actuated by rotation of the shaft (45), shaft 3 assembly extension (45a) and cam (47) in either the forward or 4 reverse direction from a neutral position. As shown in Fig. 5 2, the operator is facing laterally to the direction of 6 travel. Movement of the lever (34) to the right, or to the 7 left, engages either switch (62) or (63), closing its 8 contacts. This conditions the power circuit to drive the 9 motor (74) in one direction or the other for either forward or 0 reverse propulsion of the truck. The operator is facing 1 sideways to the direction of travel such that the movement 2 imparted to the lever (34) is consistent with that same 3 direction of travel imparted to the truck. 4 A transducer (65) is actuated by rotation of the shaft 5 assembly extension (45a) to either the right or left to vary 6 the voltage supplied to the drive motor and thus the speed in . either forward or reverse directions. 2 A cam (70) is rotated on pivot axis (52) by the collar 3 pin (50) and switches (71, 72) mounted on a carrier (73) 4 ^ opposite the cam (70) will be closed or opened, depending upon 5 the direction of movement of the collar (49) pivoting on axis j (52) by push or pull of lever (34) toward or away from the 2 operator. Referring to Fig. 3, steering auxiliary motor (75) IB drives a pump (76) supplying hydraulic fluid for the steering £ unit (77). Pump (76) also supplies hydraulic pressure for 0 operating the reach, tilt and side shift functions, controlled 1 by valve (60). A separate lift motor and pump (78, 79) 2 supplies hydraulic fluid under pressure to a control valve 3 (59) for operating the primary and secondary lift cylinders 4 (80, 81, 82) employed in raising and lowering the rails (22, 5 23) and pantograph carriage (24). Control valve (60) receives 6 hydraulic fluid from pump (76) routed through the steering 7 unit (77) such that any fluid not used for steering is 8 available to be used to operate the mast functions, namely the 9 reach, tilt and side shift through a selector valve (86). 0 Hydraulic fluid routed through steering unit (77) and through 1 valve (60) is sent to the reach cylinders (87) operating the 2 pantograph, and the tilt and side shift cylinders (88, 89). 3 Referring to the electrical circuit in Fig. 4, with power 4 being supplied by the battery (28) at terminals (90), the 5 power circuit is energized after the ignition switch (91) is 6 closed. When either the switch (62) or (63) is closed, the 1 ^ circuit is conditioned powering for drive motor (74). The 2_ amount of voltage applied to the motor (74) is controlled by 3_ the transducer (65) which is rotated by the shaft extension (45) to vary the speed. 5_ The lift, lower and other mast functions, reach, tilt, and sideshift are controlled through a solenoid card (93). 2 Depressing a selector button (41, 42, 43) on the grip conditions the control circuit for reach, tilt or sideshift. £ Movement of the lever (34) away from or toward the operator 0 causes the cam (70) to close either of switches (71 or 72) and 1 in the process, energize the appropriate solenoid. Linkages 2 (57) (Fig. 2) operate the valves (59, 60) to direct hydraulic 3 fluid to the appropriate actuating cylinder. The valve (59) 4 operates the primary and secondary lift cylinders (80, 81, 82) 5 for raising the mast and carriage assemblies. With the lift 6 motor (78) supplying power to the lift pump (79), hydraulic 7 fluid under pressure is supplied to the cylinders by actuating 8 the lift/lower control valve (59). Conversely, hydraulic 9 fluid is returned to the reservoir (96) from the cylinders 0 (80, 81, 82) at a controlled flow rate when the lever (34) is 1 pushed forward by the operator closing the switch (71), which 2 actuates a lowering solenoid valve (97) and the linkage (57) 3 shifts the spool of valve (59) to connect the metered flow to 4 return line (100) and reservoir (96). 5 The reach function of the pantograph is performed by the 6 operator first depressing the reach button (41) on the side of -10- SUSSTITUTE 1_ the grip (34) completing the circuit through the solenoid card 2! (93) to the auxiliary solenoid valve (102). Pushing the lever 3_ (34) then closes switch (71) which speeds up the steering auxiliary motor (75) through a solid state control (83) 5_ allowing hydraulic fluid from the steering valve (77) to be £ diverted to the auxiliary valve (60). Linkage (57) shifts the 2 spool of valve (60) in the direction to send hydraulic fluid £ to double acting reach cylinders (87) causing the pantograph £ to extend. Movement of the lever (34) toward the operator 0 shifts the spool of valve (60) to connect fluid under pressure 1 to the opposite ends of cylinders (87) causing them to retract 2 the pantograph. 3 Likewise, for tilting the forks back toward the operator, 4 the tilt button (42) is pressed energizing the auxiliary 5 solenoid valve (102) and tilt solenoids (103) of the selector 6 valve (86). Pulling the lever (34) toward himself, the 7 operator closes switch (72) and linkage (57) shifts the spool 8 of the auxiliary valve (60) so that hydraulic fluid under 9 pressure flows to the end of the double acting tilt cylinder 0 (88) causing the forks to tilt back a few degrees from their 1 normal vertical position. 2 Similarly, if the operator wishes to tilt the forks 3 forward, he moves lever (34) forward, the linkage (57) 4 shifting the spool of auxiliary valve (60) in the opposite 5 direction causing hydraulic fluid to flow to the opposite end 6 of the tilt cylinder (88) and exhaust the other end to the reservoir. In a similar fashion, the side shift function of the £ carriage (24) is controlled by the selector button (43). This 4_ button activates through the solenoid card (93) auxiliary £ solenoid valve (102) tilt solenoids (103, 104) and the side £ shift control valve (105) having left/right solenoid sections 2 (106, 107). Depending on whether the lever (34) is pushed £ away from the operator to shift the carriage to the left or £ pulled -toward the operator to shift it to the right, the 0 auxiliary valve (60) is actuated to supply hydraulic fluid to 1 the appropriate end of the shift cylinder (89) and exhaust the 2 opposite end. 3 The grip on the lever (34) includes the horn button (44) 4 which the operator may depress by simply pushing down with the 5 index or middle finger of his hand to sound the horn. 6 Thus, a single lever controls multiple functions with the 7 movement of the lever in the direction of the largest control 8 resistance being aligned with the larger muscle groups of the 9 operator used in operating the lever (34). The operation of 0 the valve spools of the lift/lower and the auxiliary control 1 valves (59, 60) by linkage (57) is either pushing or pulling 2 the spool overcoming the spring force. Because the valves 3 pose the greatest resistance to force, the invention provides 4 that these and other control reactive forces are laid out on 5 an axis, referred to as the "Y" axis, for operation by the 6 large back muscles, shoulder and arm in a push-pull fashion. JL This creates less fatigue and more control, giving the 2 operator better performance of the machine. In contrast, the £ actuation of the lever (34) to the right or left, as the 4_ operator is facing, referred to as the "X" axis, merely has to £ overcome the force of spring (45b) for controlling the speed £ once the switch (62, 63) for either forward or reverse 2 direction is closed. £ Moreover, the type of motion in the "Y" axis £ differentiates the function from the type of action in the "X" 0 direction. The operator simply rolls his hand and wrist to 1 operate the drive control by pivoting the lever (34) to the 2 right or left about its first axis (46). In contrast, a 3 different type of motion is employed along the "Y" axis for 4 push and pull of the lever (34) pivoting around its second 5 axis (52) for the lift, reach, tilt and side shift operations. 6 Thus, not only does the directional movement of the lever (34) 7 coordinate the least reactive force with the smaller muscle 8 group, the motion employed in developing that action is 9 distinctly different, and moreover, is consistent with the 0 human factors orientation of the mechanical operation being 1 performed, namely forward motion of the truck is produced by 2 forward motion of the lever (34) and lift of the mast is 3 produced by a pulling motion of the lever, the operator's 4 perception being of "lifting" the load. 5 Similarly, the reach/retract of the pantograph is by 6 pushing or pulling on the lever (34), coupled with depressing 2 the selector button (41), the forward or back tilt of the £ forks is performed by pushing or pulling on the lever (31) £ coupled with depressing the selector button (42) and the left 4_ or right side shift is accomplished by pushing or pulling the £ lever coupled with selecting the button (43). £ The above description of a preferred embodiment of the 2 invention is for purposes of illustration and is not intended £ to limit the exact form of the invention disclosed, which £ encompasses equivalent structures for accomplishing 0 substantially the same ends, in substantially the same way, 1 and equivalent applications are contemplated where the control 2 may be used in a variety of machines or vehicles being 3 modified appropriately to the particular equipment, such 4 modifications or variations being well within the scope of the 5 appended claims.

Claims: 1 WHAT IS CLAIMED IS: £ 1. A multi-function single-lever operator hand control £ comprising: a first "X" axis of motion lying in a single plane; £ a second "Y" axis of motion in a plane intersecting £ the plane containing the "X" axis of motion; 2 an operator's station positioned relative to said £ plane of the "X" axis such that an operator in grasping the £ single lever hand control in front of his position will be 0 alir-iing his body to said plane of the "X" axis; 1 control means responsive to the displacement of said 2 single lever hand control from a neutral position along either 3 the "X" or "Y" axis; 4 a plurality of functions controlled by movement of 5 said single lever hand control along either its "X" or "Y" 6 axis; 7 a first group of said functions oriented along the 8 "X" axis and perceived by an operator as functioning in the 9 direction corresponding to the movement of the single lever 0 hand control along the "X" axis; 1 a second group of said functions oriented along the 2 "Y" axis and perceived as functioning in the direction 3 corresponding to the movement of said single lever hand 4 control along the "Y" axis; and 5 a first resistive force imparted by said first group 6 of functions to movement of the single lever hand control from 2 its neutral position along said "X" axis perceived as light at £ the control lever as compared to a second resistive force £ imparted by said second group of functions to movement of the single lever hand control along the "Y" axis. £ 2. A multi-function single-lever operator hand control £ as set forth in Claim 1 wherein; 2 the first group of functions controlled by movement £ of the single lever hand control along the "X" axis is a £ forward or reverse function corresponding to a right or left 0 pivoting of said single-lever hand control from its neutral 1 position. 2 3. A multi-function single-lever operator hand control, 3 as set forth in Claim 2 wherein; 4 said second group of functions controlled by 5 movement of said single-lever hand control along the "Y" axis 6 corresponds to a back and forth pivoting motion of the hand 7 control lever from its neutral position. 8 4. Amulti-function single-lever operator hand control, 9 as set forth in Claim 3 wherein; 0 said control means includes variable means of 1 operating in the "X" axis in conjunction with said first group 2 of functions for varying the speed according to the degree of 3 displacement of the single lever hand control in either right 4 or left directions from its neutral position. 5 5. A multi-function single-lever operator hand control, 6 as set forth in Claim 4 wherein; 1 said control means comprises means to select one of £ said second group of functions operated when displacing said £ lever along said "Y" axis so as to isolate it from the other functions in the group. £ 6. In a powered industrial lift truck having a standup £ operator's compartment in which the operator stands facing 2 sideways to the direction of travel of the truck in either £ forward or reverse corresponding to either the right or left £ of the operator; 0 a multi-function single-lever operator hand control 1 mounted in said operator's compartment at approximately waist 2 level, said control comprising; 3 a first "X" direction of motion in a vertical plane 4 in the forward and reverse direction of travel of the truck; 5 a second "Y" direction of motion in a vertical plane 6 in the direction the operator is facing; 7 a control means responsive to displacement of said 8 single-lever hand control from a neutral position in the "X" 9 direction for controlling either the forward or reverse 0 movement of the truck; and 1 said forward or reverse control functions posing a 2 resistive force perceived as light to the operator as compared 3 to the resistive forces in the "Y" direction of operation. 4 7. In a powered industrial lift truck having a standup 5 operator's station as set forth in Claim 6, wherein; 6 said single-lever control pivots on a first axis £ that extends perpendicular to said "X" direction in a right or £ left rolling motion of the operator's hand using the small £ muscle groups of the hand and wrist and said lever independently pivots about a second axis perpendicular to said £ "Y" direction in either a push or pull motion of the £ operator's hand using the larger muscle groups of the arm, 2 shoulder and back. £ 8. In a powered industrial truck as set forth in Claim £ 7, wherein; 0 said control means comprises a first shaft rotated 1 by said single-lever hand control on said first axis, 2 a first cam rotated by rotation of said shaft; 3 a first pair of switches, one actuated by said cam 4 when rotated in one direction, the other when the cam is 5 rotated in the opposite direction; 6 a variable speed control means varied by rotation of 7 said shaft in either direction; 8 a second shaft rotated by said single-lever hand 9 control on said second axis; 0 a second cam rotated by rotation of said second 1 shaft; 2 a second pair of switches, one actuated by said 3 second cam when rotated in one direction, the other when the 4 second cam is rotated in the opposite direction; 5 said control means controlling the functions in the 6 "X" direction by operation of said first cam with said right -18- SU6STITUTE SHEET (RULE 26) 1 left rolling motion of the hand and in the "Y" direction by £ said push or pull movement of the arm, shoulder and back and £ valve means operated by rotation of said second shaft to selectively cause said functions to be performed in £ said "Y" direction. £ 9. In a powered industrial truck as set forth in Claim 2 8, wherein; £ said control means is associated with rotation of £ the second shaft to selectively cause said functions to be 10 performed and includes; 11 a selector switch actuated by the operator from the 12 single-lever hand control. 13 10. In a powered industrial truck as set forth in Claim 14 9, wherein; 15 a plurality of selector switches are arranged in a 16 row on the single lever hand control positioned so as to be 17 operable by the thumb of the operator. ££ 19

Inventors: JONES WILLIAM C JR, SEKSARIA ARUN K, JONES, WILLIAM, C., JR., SEKSARIA, ARUN, K.
Applicants: CLARK MATERIAL HANDLING CO, CLARK MATERIAL HANDLING COMPANY
Application year: 1994
Main classification: G05G9
IPC codes: B66F9, G05G9